Machines for producing pile fabrics



April 5, 1960 c. PAERSE MACHINES FOR PRODUCING FILE FABRICS 2 Sheets-Sheet 1 Filed March 19, 1958 INVENTOR PAVEVR S E BY v BM ATT NEYS CYRH.

April 5, 1960 c. PAERSE MACHINES FOR PRODUCING PILE FABRICS 2 Sheets-Sheet 2 Filed March 19, 1958 INVENTOR Pnzass CYML BY W Ma W A TORNEYS 2,931,418 MACHDIES FOR PRODUCING PILE FABRICS Cyril Paerse, Manchester, England, assignor of one-half to Paerse-Laing Limited, Manchester, England This invention concerns machines for producing pile fabrics, of the type (hereinafter referred to as of the type described) comprising a plurali y of blades which are connected together, and mounted on rollers in beltlike manner, there being means for bending a plurality of. continuous filaments each into a succession of connected loops between the lades and for applying a fluid of plastic substance, if desired with a fabric backing, to the looped filaments to provide a foundation for the fabric. An example of such a machine is described in detail in the specification of the United States Patent No. 2,583,337.

In the hitherto proposed constructions of machines of the type described the pile of the fabric produced is in the form of connected loops, and if a cut pile fabric is required it is necessary for the loops to be severed after. the production of the fabric has been completed. This isan operation requiring the provision of a complex mechanism if such is to be efiected mechanically, and which is extremely tedious if it has to be performed by hand.

It is an object of the present invention to provide an arrangement wherein the aforementioned difficulty is overcome, the filaments being severed to provide a cut pile prior to the application of the fluid or plastic.

With this in view, there is provided, according to the present invention, a machine of the type described which includes a cutting device adapted to enter between the blades to sever the connected loops disposed between the blades before the fluid or plastic is applied thereto.

Where the machine is adapted to progress the blades intermittently, and includes a plate-like element adapted to be reciprocated vertically so as to enter between successive pairs of blades to press the filaments therebetween and produce the loops when the blades are stationary, the cutting device may conveniently be mounted between such plate-like element and the means for applying the fluid or plastic, being mounted for vertical reciprocation to enter between the blades when they are stationary.

Preferably the cutting device comprises a horizontal member having a plurality of rotary cutting wheels disposed so as to project downwards therefrom, means being provided for causing such member to be displaced so that the axis of each wheel moves, on each reciprocation, firstly downwards, then horizontally parallel to the blades, then upwards and finally horizontally back to its starting position.

The invention further includes the method of making a pile fabric which comprises bending a plurality of parallel continuous filaments over a plurality of parallel blades so as to produce a succession of connected loops on each filament, severing the loops whilst held by such blades by introducing a cutting device in turn between successive blades, and then applying a fluid or plastic substance, if desired with a fabric backing, to the filaments to provide a foundation for the fabric, prior to removing the, filaments from the blades.

- The invention will be described further, by way of exblades 10a.

ample, with reference-to the accompanying drawings, in which:

Fig. l is a diagrammatic cross-sectional side elevation of a machine constructed in accordance with the inven-- tion,

Fig. 2 is a front view of the cutting device of the machine of Fig. 1, the view corresponding to arrow A in Fig. 1,

Fig. 3 is an end elevation of the cutting device of Fig. 2, the view corresponding to arrow B of Fig. 2,

Figs. 4, 5 and 6 are enlarged fragmentary details, show ing three of the stages of operation of the machine.

T he machine illustrated is basically similar to that de-' scribed in detail in the specification of United States Patent No. 2,5 83,337 and comprises a plurality of blades- 10 swingably connected together laterally (see Figs; 4- to 6) and mounted in belt-like manner on rollers 11 of small diameter. A vertically reciprocable plate-like member 12 is mounted above one roller 11 and is adapted to move downwards to press a plurality of filaments 15 passing from a feed-off roll 13 through a comb 14 to the blades 10 between a pair of the blades Illa, 18a (see Figs. 1 and 4) which is just passing to the upper run of the belt, such blades 10a, 10a being separated slightly. by the curvature of the roller 11.

Behind the plate-like member 12 and above the upper run of the belt is a doctor-blade 16 adapted to spread a vulcanisable plastic 17 applied to the upper surface: of the filaments 15 from a supply tank 18, and behind such doctor blade 16 is a guide roller 19 which serves to guide a web of backing fabric 20 from a supply roll: 21 onto the upper surfaces of the filaments 15.

Following the guide roller 19 is a heating hood 22 which is adapted to supply 23 so as to heat the plastic 17 and cause the latter to form a bond between the filaments 15 and the backing fabric 20.

A mechanism (not shown) is also provided for progressing the belt of blades 10 intermittently, a blade pitch at a time, so that the filaments 15 are progressed with the band, the plate-like member 12 being synchronised with the band in such a manner that it moves downwards and then upwards each time the band becomes stationary to press the parts of the filaments 15 which are just leading onto the band down between the adjacent pair of The arrangement, therefore, serves to pro duce a series of filament loops 15a between each adja cent pair of blades 10.

In accordance with this invention there is mounted, between the vertically reciprocable plate-like member 12' and the supply tank 13, a horizontally disposed cuttingdevice (shown generally at 24 in Fig. 1), this extending transversely of the band and parallel to the blades 10.

This cutting device 24 is shown in detail in Figs. 2 and 3. Mounted on stationary parts 25 of a frame of the machine at either side thereof are two pairs of vertical guide rods 26 whereon end blocks 27 (one at either side of the belt of blades 10) are vertically displaceable. Compression springs 28 surrounding the guide rods 26 are disposed between the end blocks 27 and the stationary parts 25 urge the end blocks 27 upwards. On the top of each end block 27 is a tappet 29' engaging a cam 30 provided on a camshaft 31 which extends transversely of the belt and is rotatable in bear ings 31 on a stationary cross-member 33 of the machine frame. Thus," rotation of the camshaft 31 causesthe cams 30 to act on the tappets 29 and reciprocate the end blocks 27 vertically, the latter moving downwards under the action of the cams 3t? and upwards under the action of the springs 28.

Extending transversely of the band of blades:10"between the two end blocks 27 are a pair of slide rods 34' heated air from a blower whereon is slidably mounted a cutter carriage 35, compression springs 41 being disposed between the carriage and the end block 27 at the left hand side of Fig. 2, so as to urge the carriage 35 to'the right as shown in Fig. 2. Projecting upwards from the carriage 35 is a thrust plate 36 and this is engaged by a cam 37 mounted on a stub axle 38 which is journalled in a bearing 39 on the crossmember 33 and which is driven, through bevel gears 40, from the camshaftj3l. Thus, rotation of the camshaft 31 causes the cam 37 to act on the thrust plate 36 and reciprocate the carriage 35 along the slide rods 34, the carriage 35 being moved to the left as viewed in Fig. 2 against the action of the springs 41 by the cam 37, and being returned to the right by the springs 41.

The shapes of the cams 30 and 37 are so chosen that, for each revolution of the cam shaft 31, the following movements occur in sequence. Firstly, the cams 30 act to move the end blocks 27 and also the carriage 35 downwards; next, the cam 37 acts to move the carriage 35 against the action of the springs 41 (i.e. to the left as viewed in Fig. 2); then the earns 30 permit the end blocks 27 with the carriage 35 to rise; and finally the cam 37 permits the carriage to move, under the action of the springs 41, back to the position illustrated in Fig. 2. Furthermore, the arrangement is such that this sequence of operations occurs each time the band of blades is stationary, so that the drive to the camshaft 31 is synchronised with the mechanism for. progressing the band of blades 10.

. Mounted in the carriage 35 are a plurality of hori zontal spindles 42, these projecting at each end from the carriage 35 and extending parallel to the direction of movement of the blade band. At one end of each spindle is a large diameter rotary cutting wheel 43, these wheels being disposed all, in the same vertical plane and each having their lowermost portions projecting downwards. below the carriage 35, as shown in Fig. 2.

. At their other ends, the spindles 42 are provided with sprocket wheels 44 and a single endless chain 45 passes around these sprocket wheels 44 so as to drive the cutting wheels 43 positively, there being a suitable drive 46 to a guide sprocket 47 around which the chain 45 passes, from a driving motor 48 mounted on the carriage 35.

The end blocks 27 also have mounted thereon pairs of support rods 49 whereon clamping bars 50, which ex tend across the belt parallel to the blades 10, are mounted. Two such support rods 49 are provided on each block 27, being pivoted thereto at 51, and these are arranged so that the cutter wheels 43 are substantially centrally disposed relative to and between the clamping bars 50. Each rod 49 has an enlarged head 52, at its lower end, defining the lowermost positions of the clamping bars 50 relative to the end blocks 27, and such bars 50 are slidable upwards on the rods 49 against the action of springs 53 which bear against fixed collars 54 on the rods 49.

Theend blocks 27 also provide mountings for wedge shaped blade separators 55, one of which is provided on each block v27 with its apex in the same plane as the cutter wheels 43. Each separator 55 is carried by a rod 56 w 'ch is vertically slidable in the respective end block 27, and is biased downwards by a spring 57.

In use, the machine aforesaid operates in a manner similar to the prior known machines. However, in contradistinction to the prior known machines, the filament lengths are severed as each blade 10 passes the cutting device 24, the following being the full sequence of operations which occurs in making a length of pile fabric.

Firstly the leading ends of filaments 15 from the feed 03 roll 13 are anchored between two adjacent blades 16 in the top run of the belt (e.g. by trapping such ends with an inserted strip of wood or other suitable material) at a position between the plate-like member 12 and the cutting device 24, but close to the member 12. The drive of the machine is then switched on, and the belt of blades 10 is progressed intermittently in the direction of the arrows in Figs. 1, moving a blade pitch distance at each progression and drawing the filaments 15 with it. Each time the belt stops, the plate-like member 12 moves once downwards and upwards, so that the filaments 15 which initially rest on the tops of the blades 10 (see right-hand side of Fig. 4) are pressed down to form the loops 15a between the blades 10 (see left-hand side of Fig. 4). The blades 10 grip the loops 15a once they have been formed, so that they cannot readily be withdrawn.

When suflicient loops 15a have'been formed to ensure adequate anchorage of the filaments 15 to the belt, the strip of wood or the like is removed, and the loops 15:: are progressed beneath the cutting device 24. Each time the belt becomes stationary, the camshaft 31 is set in motion to perform one revolution, whilst the cutter wheels 43 rotate continuously. Initially the cams 30 move the end blocks firstly, the separators 55 enter between the pair of blades 10 which is disposed below the cutter wheels 43 so. as to enlarge the space therebetween. of the blades 10, the latter may be made of a slightly flexible material, such as rubber or plastic. At the same time, the clamping bars 50 are lowered by the end blocks 27 so that they rest on the filaments 15 where the latter pass over the tops of the blades 10, as is shown in Fig. 5. The pivotal mounting of the rods 49 whereon the clamp ing bars 50 are carried permits the bars 50 to be displaced with the blades 10 as these are separated by the separators 55.

The end blocks 27 continue to move downwards (the sliding rod mountings of the bars 50 and separators 55 permitting this) until, at thebottom of the stroke of the cams 30 the cutter wheels 43 have entered between the separated blades 10 and have cut the filament loops 15a disposed therebelow. Thereafter, the cam 37 operates to move the carriage 35 horizontally along the slide rods 34 by a distance just greater than the distance between the centers of adjacent cutter wheels 43, so as to ensure that all the loops 15a are cut, thus providing, between each pair of blades 24 filament tufts 58 (see left-hand side of Fig. 5).

The earns 30 then permit the end blocks 27 to rise, so that the cutter wheels 43 and then the separators 55 and the clamping bars 50 are removed from the blades 10, whereupon the cam 37 permits the carriage 35 to return to its position shown in Fig. 2, the belt is progressed by a blade pitch, and the sequence of operations is repeated.

The belt is continuously progressed and in the manner previously described the filament tufts 58 have the layer of vulcanisable plastic17 and the backing 20 applied thereto (see'Fig. 6). finally emerges from tufted fabric, which is The fabric so made pensive, requiring no the machine as a finished pile or rolled onto a take-up roll 59.

is strong and comparatively inexfinishing, apart from conventional edge trimming after it passes from the machine. pile is dense and even and cannot readily be separated from the backing fabric.

The invention is not confined to the precise details of the foregoing example and many variations may be made thereto. For example, instead of having rotary cutters, suitable cutters having straight edges may be employed. Moreover, by suitable operation of thevcutters, or by providing a plurality of independently operating cutters, it is possible to provide an arrangement which will produce' a pattern in the fabric, which. pattern is composed ofareas wherein the pile is If desired, the backing vided a suitable plastic 17 which will form a dation for the fabric is employed.

I claim:

1. A machine for producing pile fabric comprising, a

27 (with the carriage 35) downwards and,

To facilitate separation 10 which has passed the cutting device.

The composite material so formed The.

cut and uncut respectively. fabric may be omitted, prounitary foun--- supporting structure, an endless belt including a plurality of blades having relatively hinged inner edges for separation of adjacent blades, spaced rolls in said supporting structure supporting said belt with a run thereof for alternate longitudinal movements and stationary periods, said blades having outer edges transversely of said belt for supporting contiguous continuous bendable filaments longitudinally of said run and means for applying said filaments to said edges of the blades, looping means for displacing filaments on said edges of the blades inwardly between adjacent blades to form loops therein between said blades, separator means operable for entering between and separating adjacent blades for the action of cutter means on the loops between said blades and clamp means operable with said separator means to clamp filaments to outer edges of said separated blades, cutter means operable to enter between said separated blades to cut loops therebetween, said looping, separator, clamp and cutter means operable in stationary periods of said run, and means for applying a backing to the filaments on outer edges of the blades following operation of the cutter means.

2. A machine set forth in claim 1 wherein said looping means includes a plate-like member disposed transversely of said run of the belt which is reciprocable towards and away therefrom.

3. A machine set forth in claim 1 wherein said separator means includes members adjacent opposite sides of said run of the belt which are reciprocable towards and away therefrom.

4. A machine set forth in claim 1 wherein said separator means and said clamp means are yieldingly mounted for reciprocation towards and away from said run and said clamp means includes elongated bars at opposite sides of the separator means movable towards and away therefrom.

5. A machine set forth in claim 1 wherein said cutter means includes a plurality of rotatable cutters spaced transversely of the said run of the belt and being movable towards and away from said run and in opposite directions transversely thereto.

6. A machine for producing pile fabric comprising, a supporting structure, an endless belt including a plurality of blades having relatively hinged inner edges for separation of adjacent blades, spaced rolls in said supporting structure supporting said belt with a run thereof for alternate longitudinal movements and stationary periods, said blades having outer edges transversely of said belt for supporting contiguous continuous bendable filaments longitudinally of said run and means for applying said filaments to said edges of the blades, looping means for displacing filaments on said edges of the blades inwardly between adjacent blades to form loops therein between said blades, guide means at opposite sides of said run, end members slidable downwardly and upwardly on said guide means and slide rod means disposed transversely over said run connected at opposite ends to said end members, means to move said end members downwardly in stationary periods of said run and means to urge said end members upwardly, separators yieldingly mounted on said end members to enter between and separate adjacent blades in downward movements of said end members for operation of cutters on loops between said separated blades, clamp means disposed transversely over said run at opposite sides of said separator yieldingly mounted on said'end members and being operable simultaneously with said separators to clamp filaments to outer edges of said separated blades, a carriage slidable in opposite directions on said slide rod means having a plurality of transversely spaced rotatable loop cutters thereon operable between separated adjacent blades and means to rotate said cutters, means to move said carriage in one direction and means to urge said carriage in an opposite direction, all adapted and arranged whereby in movements of said end members downwardly and upwardly said cutters are moved downwardly and transversely in one direction between separated blades to cut filament loops therebetween and then upwardly and transversely in an opposite direction.

7. A machine for producing pile fabric comprising, a supporting structure, an endless belt including a plurality of blades having relatively hinged inner edges for separation of adjacent blades, spaced rolls in said supporting structure supporting said belt with a run thereof for alternate longitudinal movements and stationary periods, said blades having outer edges transversely of said belt for supporting contiguous continuous bendable filaments longitudinally of said run and means for applying said filaments to said edges of the blades, looping means for displacing filaments on said edges of the blades inwardly between adjacent blades to form loops therein between said blades, end members at opposite side edges of said run guided in said supporting structure for movements downwardly towards and upwardly away from the plane of said run, slide rod means extending transversely of said run secured at opposite ends to said end members, means operable in stationary periods of said run to move said end members downwardly and means to move said members upwardly, separator means for entering and separating adjacent blades and clamping means for clamping filaments to the other edges of separated blades yieldingly mounted on said end members for simultaneous operation in downward movements of said end members whereby filament loops between separated blades may be cut, a carriage movable in opposite directions on said slide rod means having a plurality of rotatable cutters thereon spaced transversely of said run and means to rotate said cutters, means operable in stationary periods of said run to move said carriage transversely in one direction and means to move said carriage in an opposite direction whereby in downward and upward movements of said end members said cutters move downwardly between separated blades and transversely in one transverse direction to cut filament loops therebetween and then upwardly and in an opposite transverse direction.

References Cited in the file of this patent UNITED STATES PATENTS 

